Rail bond



Jul y r.18, 193 H. P. CHANDLER RAIL BOND Original Filed Jan. 4, 1956 Inve Attorney flea 9. 266110) Homsue P 6' a 4 a J a a a m a 1 m f H M f "which is inexpensive to construct and which pos- Patented July 18, 1939 RAIL BOND Homer P. Chandler, Mansfieldrohio, assignor to The Ohio Brass Company, Mansfield, Ohio, a corporation of New Jerse Application January 4, 1936, Serial No. 57,568 Renewed -May 5, 1939 20 Claims. (Cl. 173-280) My invention relates to electric connectors and the portion 9 of the pin 8 into the passage 1 until particularly that class of connectors called rail the end face l3 engages the end of the conducbonds for electrically connecting the adjacent tor 6. ends of conductor rail's. I prefer to make the portion 9 of the pin such The object of my invention is to provide a bond that when the face I3 engages the conductor, the

shoulder II will not be in contact with the face ll of the sleeve 3, as shown in Fig. 11.

Having loosely assembled the parts as shown in Fig. 11, I then apply pressure to the parts in suit able dies whereby the pin 8 is forced up into the terminal through the passage 1 against an opposite force applied to the head of the terminal, while the sleeve 3 and button iii are encased in a die of proper diameter for the finished terminal.

The application of the force in this manner tends to crowd the strands l5 of the conductor 6 into substantially a solid mass in intimate contact with the end face iii of the pin 8. Simultaneously the end portion ll; of the pin within the terminal is expanded to a size larger than the passage 1 and thus interlocked with the head 4. The crowding of the pin into the body tends to completely fill the passage 1 and expands the sleeve 3, and simultaneously expansion of the button l0 takes place, thus bringing the sleeve and button ID to a uniform size, which is preferably a size to just permit the terminal to be inserted in the rail opening.

The diameter of the sleeve 3 and the button l0 is uniform throughout their length.

In Fig. 12 I have shown in section a bond terminal installed in the head of a rail. The rail is first drilled to form an opening H. The depth of the opening issuch that the shoulder l8 of the terminal will not seat on the face of the rail when the face I! of the-button I0 is bottomed in the hole, as indicated by dotted lines in Fig. 12.

Having positioned the terminal in the rail opening, force is applied in the direction of the arrow (see Fig. 9) either by means of a hammer or press. This force tends to drive the steel terminalinto the opening forcing the metal in the button l0 ahead of the sleeve, and as soon as the metal in the button "I has substantially filled the bottom of the opening l'i, any further movement of the terminal will cause the metal of the pin 8 to flow through the passage 1 into the head 4.

sesses high electrical efliciency, is simple and inexpensive to install and which provides a permanent mechanical joint with the rail.

My invention resides in the new and novel construction; combination and relation of the parts hereinafter described and shown in the attached drawing.-

In the drawing:

Figs. 1, 2 and 3 are side, end and face views respectively of a portion of the terminal member.

Figs. 4 and 5 are side and end views respectively of a pin which I use.

Fig. 6 is a side view of my complete invention.

Fig. 7 is a top view of my invention shown in Fig. 6.

'Fig. 8 is a sectional view of the terminal taken on the line l8 of Fig. 6.

Fig. 9 is a view in partial section of the terminal taken on the line 9-9 of Fig. 7.

Fig. 10 is a sectional view taken on the line Iii-l0 of Fig. 7.

Fig. 11 is a view in partial section on the line 8-4 of Fig. 6 showing the preliminary assembly of the parts and before the assembly has been completed.

Fig. 12 is a sectional view showing the terminal installed in an opening in the side face of a rail head.

In the preferred embodiment of my invention I form up a body member I preferably of ferrous metal. This may be done by hot forging or by extremely high cold pressure. The body is formed with a projecting sleeve 2 and a projecting sleeve 3, and a head portion 4.

The sleeve 2 is drilled to form the passage 5 to receive the end of a conductor 6, and the sleeve 3 is drilled to form the passage 1 to receive the plug or pin 8. The passages 5 and 'l intersect within the head portion 4.

The pin or plug 8 is easily and cheaply formed from rod, and I prefer the plug to be of copper. The plug has an elongated, reduced portion 9 and an enlarged button portion ill with a shoulder H. The exposed end face I2 of the button may be plain or conical shaped. The latter is shown in Fig. 4.

- Having formed the parts I, 6 and 8, they are then loosely assembled by inserting the end of the conductor into the passage 5 and inserting and at the same time expand the sleeve i3 into contact with the walls of the opening l'l.

With the proper depth of opening I! with relation to the projection of the shoulder l8 from the face of the rail, it will be found that when the shoulder l8 engages or substantially engages the face of the rail, that the button l0 and the sleeve This will tend to further compact the strands l5 3 will have been forced into secure engagement with the entire surface of the walls of the opening I! thus producing a highly efficient connection. both electrically and mechanically.

5 The pin 8 being of copper and in direct contact with the conductor 6 and the rail I9, the resistance of the bond, hence of the Joined rails, is-materially reduced as against a bond in which the terminal is entirely of ferrous metal, thus 10 introducing considerable resistance between the conductor and the rail.

As the plug is forced into the rail cavity and expands, it tends to harden. This is especially true if the plug is of copper, and I find that this hardening assists in crowding the walls at the bottom of the rail opening to increase the diameter of the opening at the bottom thus forming a'slight interlock of the rail and bond terminal.

\ Modifications will suggest themselves to those skilled in the art, therefore, I wish to be limited only. by my claims.

I claim:

1. A rail bond comprising a terminal connected to a cable, said terminal comprising a metal body having a passage extending part way therethrough receiving the end of the cable, a projecting portion to be inserted in an opening in a rail, a second passage extending coaxially through the projecting portion substantially at right angles to the axis of the first passage and intersecting the first passagewithin the terminal and a covering of metal over the intersection of the passages and cable, said terminal further pro-.

vided with a separately formed plug of metal having a portion positioned in the second passage with its end engaging with the cable end in the first passage and an exposed portion projecting from the end of the projecting portion on the terminal and of the same diameter, the

projecting portion of the terminal and plug being adapted to be expanded in the opening in the rail when force is applied to the aforesaid covering of the terminal body.

2. A rail bond comprising acable and a terminal attached to an end thereof, the terminal comprising a metal body having two projecting sleeves with axes angularly disposed to each other, each sleeve having a passage which intersects with the passage of the other sleeve, 2. portion of the body covering the point of intersection and one passage receiving the end of the cable and one sleeve being adapted to be inserted in an opening .in a rail and a separately formed plug of a metal softer than that of the terminal body extending through the passage in the last said sleeve and into secure contact with the cable and also projecting without the sleeve from the end thereof, the projecting portion of the plug being of the same diameter as the sleeve from which it projects, the last said sleeve and plug adapted when inserted in the said opening in the rail to be expanded therein when force is applied to the terminal body.

3. A rail bond comprising a cable and a terminal, said terminal comprising a body member having two intersecting passages with angularly disposed axes, a portion of the body enclosing the passages at their point of intersection, a

projecting sleeve through which one of the passages extends adapted for insertion in a rail opening, a pin positioned in the passage extending through the sleeve and projecting without the sleeve in alignment therewith, said cable having an end positioned in the other passage in contact with the concealed end of the pin.

4. A rail-bond comprising a cable and a terminal, said terminal comprising a body member having a passage therein, a projecting sleeve 5 adapted to be secured in a rail opening, a passage through said sleeve in alignment therewith and intersecting the first passage, a pin positioned in the last said passage and projecting exterior of the sleeve, said cable having an end 10 positioned in the first passage and secured therein by compression between the concealed end of the pin and a portion of the body member, the sleeve and projecting portion of the pin being adapted to be expanded in the opening in the 15 rail.

5. A bond terminal comprising a body of metal, a'projecting sleeve having a passage extending therethrough to the interior of the terminal, a second sleeve having a passage extending there- 20 through and intersecting with the first passage,

a separately formed plug mounted in the second passage with a reduced portion extending into the first passage and an enlarged portion projecting from the free end of the second sleeve 25 and forming a shoulder against which the end of the second sleeve abuts, the second sleeve and projecting portion of the plug being adapted to be inserted in a rail opening and expanded therein through force applied to the body member. 30

6. A bond terminal comprising a body of metal, a head portion and a portion of uniform diameter projecting therefrom, a passage of uniform diameter through the projecting portion and terminating in the head portion, a separately formed 35 pin having a portion of the same diameter as the aforesaid projecting portion and a portion positioned in and of the same diameter as the said passage, the two portions of the pin forming a shoulder abutting against the end face of said 0 projecting portion with the larger portion projecting from and in axial alignment with the projecting portion from the head, the said larger portion of the pin and the projecting portion of the head being adapted to enter and be expanded u in a rail opening.

7. A bond terminal for application to an opening in a rail comprising a body having a. portion of uniform circular cross-section, the said portion having a passage of uniform circular cross-section and a plug having a relative large portion of uniform circular cross-section of the same diameter as that of the body portion and a smaller portion of uniform circular cross-section of the same diameter as the said passage, the smaller portion of the plug being positioned within the said passage and the shoulder formed between the said portions of the plug being seated against the end face of the body portion, the body having a second passage intersecting with 60 the 'first passage to receive a conductor end, the end of the plug within the body projecting into the said second passage.

8. The method of manufacturing rail bonds comprising the steps of preparing a conductor 05 of proper capacity and length, forming a metal body member, having two angularly disposed intersecting passages, forming a pin having a large diameter portion and a small diameter portion, passing an end of the conductor into one of the passages, passing the smaller diameter portion of the pin into the other passage, subjecting the assembled parts while cold to pressure to force the body into close engagement with the conductor, to force the larger portion of the 7 the rail through force applied to the terminal pin into the body and into close engagement with the conductor to force the larger portion of the pin against the end of the projecting portion on the body and to size the said projecting portion and large portion of the pin to a uniform and required diameter.

9. In combination, a rail bond terminal of deformable relatively hard metal having a projecting part adapted to be positioned in a rail cavity, a channel partly within said projecting part, a

relatively soft metal plug positioned in a part of the channel, said plug projecting therefrom and arranged to engage the end wall of the cavity to expand the terminal into engagement with the side wall of the cavity when the terminal is forced into the cavity and a conductor positioned in the remainder of the channel and projecting therefrom, the plug and conductor being in intimate contact.

10. A rail bond comprising a cable and a terminal, said terminal comprising a body portion having a passage therein and a projecting sleeve portion having a passage therein intersecting the first passage, a pin having a portion positioned within the second passage ,and having an enlarged end within the terminal interlocked with the terminal to prevent disassembly and a second portion projecting exterior of the sleeve, said cable having an end positioned in the first passage and held in compression between the body portion and the enlarged end of the pin, the sleeve and pin projections arranged to be positioned in a cavity in a rail and expanded therein to provide an electrical and mechanical connection between the pin and rail.

11. A rail bond comprising in combination a terminal and a cable, said terminal comprising a body portion having a passage therein and a sleeve portion projecting from the body portion, a pin extending axially through the sleeve and projecting from the free end of the sleeve, said cable having an end positioned in the said passage and engaged by the enclosed end of the pin, the sleeve and projecting portion of the pin adapted to be positioned in a cavity in a rail and expanded into contact with the rail through force applied to the exposed body portion of the terminal.

12. A rail bond comprising a cable and a terminal, said terminal including a metal body portion having a passage therein, said cable having an end secured in the passage, said terminal further having an integrally formed sleeve projecting therefrom, a pin of metal softer than that of the body member extending axially through the sleeve and engaging the enclosed end of the cable and projecting from the free end of the sleeve, the sleeve and exposed portion of the pin of said terminal adapted to be positioned in a cavity in a rail and expanded into contact with the rail through force applied to the terminal portion exterior of the rail.

13. A rail bond comprising in combination a cable and a terminal secured thereto, said ter minal comprising a metal body portion having a passage therein and an integrally formed sleeve portion projecting from the body portion and a pin of copper extending axially through the sleeve and projecting from the free end of the v sleeve, the cable having an end secured in the passage and in engagement with the enclosed end of the pin, the sleeve and projecting portion of the pin adapted to be positioned in an opening in a rail and expanded into contact with exterior of the rail.

14. A rail bond comprising in combination a cable and a terminal secured to the end thereof, said terminal comprising a metal body portion having a passage therein and an integrally formed portion projecting from the body for p siiioning in a cavity in a rail and copper means extending axially through the projecting portion and arranged to contact with the inner Walls of the rail cavity, said cable having an end secured in the said passage in engagement with the pepper means. the copper means being adapted to securely engage the inner walls of the cavity in the rail through force applied to the terminal portion exterior of the rail.

15. The combination with a rail having a cavity of a rail bond comprising in combination, a terminal and a conductor secured thereto, the terminal comprising a body of relatively hard metal having a relatively low electrical resistance, and a projecting portion positioned within the cavity in the rail, the said portion being of less length than the depth of the cavity, a tip of relatively soft metal having a relatively high electrical conductivity, means to secure the tip to the end of said portion, the combined length of the tip and of said portion of the body when first positioned in the cavity being greater than the depth of the cavity, the tip being arranged to engage the end wall of the cavity and to be expanded and forced into engagement with, the inner side wall of the cavity to secure the terminal in place when force is applied to the exposed portion of the body to force the said projecting portion into the cavity.

16. A rail bond comprising a cable and a pair of terminals, each terminal comprising a steel body member having an integrally formed projecting portion adapted to enter a rail cavity, said cable having its ends attached to the body members and connecting the terminals, each body member being provided with a tip of copper of the same diameter as the said projecting portions and projecting therefrom, the projecting portion and tip adapted to be positioned in and the tip expanded into. engagement with the inner walls of the rail cavity simultaneously with the forcing of the projecting portion into the cavity and "means of copper connecting the tip directly to the conductor I I 17. The combination of a rail with a cavity of limited depth and a rail bond comprising a conductor and a terminal attached thereto, the terminal comprising a deformable steel body provided with a cup-shaped projecting portion open at its free end and arranged to be inserted in the rail cavity with the open end towards the end wall of the rail cavity, a plug of copper positioned axially in the recess of the projecting portion and projecting from the fre end of said portion and of the same diameter as the said portion, the projecting portion of the plug arranged to contact with the end wall and the side wall of the cavity and the entire plug being expandable to force the Walls of the cup-shaped projecting portion into engagement with the side walls of the cavity when force is applied axially to the steel body and copper core to force the cup-shaped portion into the cavity'.

18. The combination with a rail having a cavity of a rail bond comprising a terminal and a conductor secured thereto, said terminal including a body portion of ferrous metal and an integral projecting portion for insertion in a cavity in a rail, the said portion being 01 less length than the depth oi the cavity, a tip of nonierrous metal secured to the end iace of said portion, the combined length of said portion and tip exceeding the depth oi the rail cavity when first positioned in the cavity the tip being arranged to engage the end wall oi. the cavity and to be expanded into holding engagement with the side wall of the cavity when force is applied to the exposed portion of the body to force the said projecting portion into the cavity.

19. A rail bond comprising a cable and a terminal secured together, said terminal comprising a metal body having an integrally formed portion projecting therefrom to be secured in a rail cavity, a tip of metal softer than that of the body member and or the same diameter as the projecting portion secured to the end of the projecting portion, the projecting portion and the tip adapted to be positioned in a rail cavity and the tip to be expanded by the projecting portion into holding engagement with the side and end walls of a rail cavity when force is applied to the terminal axially oi the projecting portion and means iormed integrally with the tip and extending into the projecting portion to anchor the tip to the projecting portion.

20. A rail bond comprising a cable and a terminal secured together, said terminal comprising a body of ferrous metal having an integrally formed portion projecting therefrom to be secured in a rail cavity, a tip of non-ferrous metal of the same diameter as the projecting portion secured to the end of the projecting portion, the projecting portion and the tip adapted to be positioned in a rail cavity and the tip to be expanded by the said projecting portion into holding engagement with the side and end walls of a rail cavity when force is applied to the terminal axially oi the projecting portion and means formed integrally with the tip and extending into the projecting portion to anchor the tip to the projecting portion.

HOMER. P. CHANDLER. 

